Another inexpensive tool worth every penny

I've removed the rear wheel and tire from most of my bikes at least once. For the shaft drive Kawasaki Concours, it's an easy if somewhat cumbersome process getting the wheel back in place and everything lined up.

For my Harley-Davidsons it's a completely different problem. I can imagine it's the same for chain drive bikes, but I haven't owned one in a long time. Getting the wheel into place and the axle through is fairly easy, as a rear wheel without a gear drive attached is much lighter. But then the fun starts, getting the proper chain or belt tension and the rear wheel and axle aligned so the bike tracks properly.

What a PITA! Being cheap, I originally didn't buy an alignment tool-how hard could this be? Really hard, so I broke down and bought a simple tool.

Best $16 I've spent on a bike ever! Get the tension you need, use the tool to mark the distance on that side of the bike (yes, Harley Sportsters but the belt on the "other side"!), go to the opposite side, slide axle into alignment, tighten everything, check again, torque everything and go for a "test ride"!

Full Disclosure, I am an Amazon Associate and will receive a small percentage of sales made through the link.

Cheap motorcycle tools that are very valuable for maintenance

Do you work on your own bike? Especially the routine maintenance that gives you time checking your bike and a feeling of accomplishment when you are finished with the task?

I do, and normally enjoy it and find it a good opportunity to check things out, spend some time doing mechanical things which is quite different than my normal day, and have that confidence that while I can't repair complex parts of the bike, I can take care of routine items myself.

The frustration comes when a project should be simple, but turns out to be overly complex or messy. One great example is changing the oil on a Harley-Davidson. Everything is pretty much right there out in the open. One hallmark of the Harley twin-v design is the oil filter placement forward of the front cylinder-looks good, works like a bit of an oil cooler, and makes accessing the filter for oil changes straightforward. Put an end cap filter wrench on, rachet drive with an extension and off it spins.

That's where things go wrong. About half a turn in and oil starts leaking out from the engine case all over the lower portion of the engine. I had tried all kinds of "solutions" on multiple twins-newspaper, cut up 2-liter "coke" bottles, tin foil. All worked to some degree, but all were also messy or a lot of effort for a simple job.

Then a friend let me borrow his oil change funnel kit. Available from a variety of manufacturers, these are purpose molded funnels that solve this problem, and the primary case fill problem too. A hard plastic funnel slides under the filter, has a drain and small rubber tubing to take oil right to your drain pan. A really good set is available on Amazon here, and for full disclosure (thank you nanny state) I am an Amazon Associate and get a few pennies if you buy from that link.

This is a simple tool, many companies offer a variety of them for less than $20, and the simplicity of doing oil changes with it is very welcome. I'll feature another simple but elegantly time-saving tool soon. Thank you for reading!

Great Weekend Riding and Upcoming Projects

Quick report on my busy weekend, about 350 miles of riding, and some projects I have coming up on the  bikes.

Saturday I was at the Long Beach International Motorcycle Show (IMS) almost all day.  After meeting my CMA chapter for breakfast, four of us rode up there on our bikes while a few others "caged" there.  Only one wrong turn as the "trying to get fired Road Captain" and we made it in plenty of time to get the Helmet and Gear check going.  Only problem was we had less space than last year and no where near enough.  We had to shut the check down for about half an hour in the mid-afternoon, re-organize the helmets and consolidate a rack or three of jackets and then re-open.  Bummer, but the other option would have been to have gear tags out of order-a true recipe for disaster!

Sunday I participated in the El Cajon Harley Owners Group (HOG) Toys for Tots run.  Great event, great guys running it with lots of volunteers and a great cause.  Fun part for me was it was a "controlled ride" meaning we stayed as a group and had police escort.  However there were more intersections than Road Captains from HOG, so I started helping out.  Fun to do that every now and then as we "quickly" rode from intersection to intersection alongside the nearly 200 bike group.  Ride ended at Del Mar Racetrack where we rode in (quietly to not spook the non-iron horses) and had our own area.  Best part?  Nearly 2300 toys for Toys for Tots, and over $8000 that will also go for toys and gifts! 

After my annual pre-Thanksgiving Dinner ride before joining family at the in-laws, I have a number of projects on the two Connies.  The restoration bike (94, aka Belle) needs an oil change and general check-up, plus I may test fit the sanded and repaired bodywork. Belle's tank was going to go on the old 86 (Miss Swail) but the petcock leaks and trying to get it off one of the mounting nuts came loose from inside the tank.  UGH.  So I'm going to see what can be done with the old parts bike tank I've had sitting around.  It's nasty but if it holds gas it may have to do to get the bike sold and I'll let the new owner decide to use some gas tank sealant on it or buy a replacement on eBay.

Could you help me out and click this link for some metric T-handle wrenches?  Testing out the Amazon Affiliate program and would like to see how a sale or two works.  Thank you!

New Rear Tire For the Kawasaki Concours

The rear wheel and tire I put on the 86 Connie from the 94 had gotten smooth on the middle like most of my tires, so it was time for a new rear tire.  This will be the last one before this bike gets to be 100k more miles than the 94 and retired.

So Friday night I put the bike up on its centerstand, but this time I decided to pull the mufflers just to see how much easier that makes this process.  It's a big difference, and more on the second project that started .

I haven't used a 27mm socket for this project, which is the right one for the crown nut.  I got everything apart and dropped the wheel and new tire off at Poway Motorcycles, my usual shop for remounting tires.  They did their usual quick and effective work.  I picked up the wheel but I also ran by Harbor Freight and picked up a 27mm socket.  What's the point of doing a project if you don't get to buy a new tool?

Everything lined back up pretty well-easier than usual to get the axle back through.  Having the socket instead of improvising a way to hold the crown nut and tighten the axle was much easier, and getting the nut tightened up and a cotter pin through the axle.

With the muffler "cans" off I decided to sand them down and try repainting them.  Even though I plan on selling the 86 as a parts bike/first Connie for someone else, the cans will look better and I'll get the experience with high heat paint.  So last night I sanded them to prep for paint.  Today is a bit cool and overcast, so I'll paint them tomorrow. 

30-year old Kawasaki emblem "goo" finally met it's match

My everyday ride is a 1986 Kawasaki Concours, one of three I have owned.  One was a parts bike, and one is the 1994 Concours I'm slowly restoring.  Well, both the other Connies have bad gas tanks-the parts bike tank was an internally, faded paint mess, and the 94s has rusted through from sitting too long.  It's been repaired, but also isn't in as good a shape as the 86 tank.

So I'm going to re-use the 86s tank for the restoration but need to repaint it.  I popped the Kawasaki emblems off a few weeks ago, but big black blobs of adhesive were left behind.  Nothing that should have worked got this stuff off.  Even after thirty years no solvent I dared use dented the blobs.

I asked my Father-in-Law if he had a heat gun, but he didn't.  So what did they get me for Christmas among other things?  Yep, a heat gun!  (side note:  You know you're getting old when a heat gun excites you more than possibly getting a Red Rider BB Gun.)  So tonight after dinner I went out to the garage, grabbed a plastic putty knife and fired up the heat gun.  Once softened a little the adhesive "goo" came off.  I slightly melted the putty knife, but no big loss-it was one I found laying around and not sure when we got it.

I've already got another project or two in mind for the heat gun, so it will likely be put to good use.  Time to prep a few more pieces of old bodywork and pick a color for the Connie-bouncing between a dark blue, a deeper red than stock, or white and black. 

Quick Post-Update on Connie Projects

Being TWO (Two Wheels Only) for seven months now and not traveling for work anymore has meant lots of miles but also lots of wear and tear on the Connies.  Here's a quick update on projects, maybe I can post more specifics on what I did and why in future posts.

1986 Connie

Rolled it over 100,000 miles
Cracked the Main Fairing Bracket (again)
Stripped main fairing off and removed bracket for neighbor to re-weld (again)
Changed Front Tire
Changed Oil
Had a pinhole radiator hose leak (see 1994 Connie projects...)
Removed and re-installed hard bags and antlers

1994 Connie

Used as transportation bike for almost 1,000 miles/good shakedown
Had a friend repair tank leak
Killed two fuel filters in four days using said tank due to rust inside it/replaced fuel filter three times (lol-but wasn't funny limping a starving for fuel bike home twice in four days, including some roadside networking with a Sheriff Deputy!)
Relocated 1986 tank and bodywork and spare bodywork to make 1994 all red
Moved/removed antlers and hard bags for commuting use, then back to 1986
Re-bleed front brakes but still too soft.  Replaced pads but still not gripping right
Drained radiator fluid and scavenged down pipe and hose for use on 1986
Documented brake and fork repairs needed prior to returning to full-time use

So I've been using 2.5 Connies to keep one on the road.  Tomorrow I celebrate 7 months of not owning a truck or car for me and only occasionally using a family members or friends!

Keep the knees in the breeze friends!

Winter Riding in California and the Start of BikeBandit sales

Yep, it's that time of year again.  Winter riding.  After suffering through the hot dry summers out here that last until late October-it's routinely 85 plus degrees on Halloween, it's "winter".  Or at least the calendar says so.

So your intrepid blogger soldiers on-riding year round and dealing with the brutal hardship of winter riding.  Getting on the bike before sun-up requires layers upon layers of clothing, no exposed skin and extra time to ensure the cold battery starts up the nearly 30 year old 1986 Kawasaki Concours, AKA Connie AKA C10 AKA Miss Swail.  Off I ride into the brightening sunlight, cold air finding every bit of exposed flesh and tearing through my jeans.  Hey, it's probably below 50!  C'mon this is brutal.

Then it gets even worse as the sun gets up and by mid-morning it's warming up through the sixties.  Now what do I do with all these layers?  Fortunately I'm running the sidebags on the Connie so they both fill up with gear and extra clothes.  I'll probably make it home before sunset, so I'll probably ride home in my long sleeve shirt and leave the jacket rolled up in a side bag.  Yep, it's tough riding in the winter!

All sarcasm aside, it is pretty odd reading about folks taking their "last ride for the winter" and elaborate winterizing procedures.  The forums light up with arguments about putting the tires on plywood, cardboard or how often to roll the bike a quarter wheel diameter.  Battery in or out?  Oil change before AND after storage, or just before?  All the while I'm thinking "Just ride it" but then I watch Buffalo get 7 feet of snow (YIKES!) and realize how good I've got it.

So do you need more layers of gear, motorcycling maintenance supplies like I do because you're  riding more due to time off, or winterizing oils and tools?  No matter what, it's Black Friday and Cyber Monday sales time, and BikeBandit.com is having all kinds of sales starting today.  So click on a banner, get anywhere from a 36-90% discount, and get what you need delivered to your door!  No need to brave the snow and ice, or crazy commuters-have the parts sent to you.  I wonder if they sell tire stud kits? :-)

The Return of the BikeBandit.com Daily Deal and a chance to win a $5,000 Alpinestars shopping spree

Yeah, while  the Daily Deal might have gotten your attention the chance to win big bucks probably grabbed you!

First, here's today's Daily Deal:  An Arctiva Comp 7 RR Shell Jacket at an up to 52% off!  As a closeout item, limited sizes and colors are available, so hurry on over to BikeBandit.com and check out your favorite and get one while they last.  At the time of this post, only large sizes in black remain at $109.95-a good saving and this qualifies for free shipping.  Lots of sizes remain in blue with red trim and the high-vis orange jacket, and both these colors are priced at over 1/2 off at $79.95.  Throw in an oil filter, some other accessories and get over the threshold for free shipping and you get a great deal!

Ok, now for the details on the Alpinestars contest.  Buy $100 of Alpinestars products before shipping and tax (hmm, I bet most qualifying purchases might also qualify for free shipping!) and you are automatically entered.  So whether you need new boots for desert and dirt season, a new jacket for cool weather riding, replacement sliders and buckles, or just some cool Alpinestars swag, click on any of the BikeBandit.com links or banners on this blog, do some shopping, and you could win a $5,000 shopping spree!  Just imagine how much more cool Alpinestars gear you could have for yourself, your friends, and yes, your faithful blogger!

Ride it like you stole it-unless you stole it, then give it back and buy your own bike!

BikeBandit Daily Deals and Tires and Tubes on SALE!

Just a quick post, as I saw a great Daily Deals e-mail from BikeBandit this morning.  The latest street riding gear is on sale-some up to 43% off.    The specific Daily Deal is a Scorpion EXO 500 helmet for only $139.95 with free shipping, like all BikeBandit orders over $99.

Also they are running great deals on tires and tubes, so if you need some new tires for late fall and winter riding, or new tubes and tires for your dirt and dessert tires now that those seasons are upon us, click on one of my links to visit BikeBandit, check out the deals, and help out my affiliate marketing program with them.  You can also pick up shop tools for your garage and parts needed for that next round of motorcycle maintenance you know you're going to have to do sometime soon.

Have a great weekend with family, friends and riding!  I know I am.

Quick update related to yesterday's post and time to do some BikeBandit shopping

Yesterday I FINALLY got back in the wind and it had probably been over a month since I have ridden.  I sold my Sportster earlier this year, had the 1994 Connie apart for restoration, and then lost the headlight on the 86 Connie.  So I started troubleshooting the 86 but couldn't solve the problem quickly, as I detailed in earlier posts about electrical gremlins.  I was going to scavenge parts from the 94, but that didn't work either.  Short on time and traveling for work, I began using my truck.  One week turned into two, into more work travel and next thing I know I hadn't ridden in far too long.  Monday my truck decided to also not run right (it's old, carbs still aren't quite set-up right, blah blah blah) and I had to get something else on the road.

So I did, and riding yesterday was great!  Sure some of it was riding in evening rush hour traffic, but at least I was on a bike!  Being in California, I also could "filter" or lane-split/share, a huge benefit both time and sanity wise.  Having not ridden I am adding a few extra miles to rides even.

With all that said, I realized I haven't changed the oil in "Belle" the 94 since I bought her in February and have no idea how long the oil was in the bike before that.  I need a filter and some parts for the CB 750 project bike, so I'll be on BikeBandit later today getting some motorcycle maintenance supplies.  I'm looking to do a Concours oil change, re-assemble the Honda CB750 as a rolling chassis at a minimum.  Depending on time and having another strong back to help I may even re-install the engine.  But I also want to ride!

Keep it dirty side down-or if you run rat bikes or beater-style, dirty side up and down!

ABS Plasitc bodywork repairs

My 1994 Kawasaki Concours has some damaged bodywork from previous owners having a small wreck and being laid down at low speed.  The side panels and the belly pan all had scrapes and damage on them although the paint is in pretty good shape.  Since I can't do bodywork and these are old bodywork made out of ABS plastic, I reached out to a friend of mine.  He had helped me repair a previous dent and looked forward to trying ABS work.

A few weeks ago we had a planning and evaluation get together.  We went to NAPA and looked at options, and the best one was getting fiberglass resin but not use any cloth.  Work got in the way for both of us, so we weren't able to get back to the project for too long.  So one night he experimented without me.  He laid a thin layer of the resin on the damaged areas and let it set up.  So yesterday I went over and we looked at the parts in the bright San Diego sun.  By "flowing" the resin across the panels the long scrapes were built up and the cracked areas were sealed together.  They aren't fuzed like ABS plastic welding would have done but they seem to be stiff enough.  He handed me a vibrating sander with 220 grit paper and I went to work on them.  I learned a good lesson after hand-sanding all my bikes previously!  I'm shopping for a sander soon!

We also cleaned up some areas with a dremel tool and checked the parts back and forth.  The usual rule of thumb applies-sand at least 1/3 more time than you think you needed to.  The resin worked really well for this project after the first sanding, so Larry mixed up a small patch of the leftover resin and activator.  We spread another thin coat on the low spots and set the parts out in the sun.  The next step will be to get the parts from Larry's and sand them with both 220 and 400 grit prior to filler priming.

I hate to say it, but Larry is going to make these parts look brand new-which means I'll be crying when they get the road scars I know this bike will!  It's stable mate is my 100K project bike and it's definitely picked up it's share of rock chips, scrapes and other "road trophies".

1986 Kawasaki Concours Electrical Gremlin Update

Back home from a week traveling for work and visiting family but not on the bike.  Connie battery dead-very little charge.  I think I either put this battery in when I bought the bike, or it was in it when I bought it in early 2010.  Since the bike sat for two years it's old but also been used.  I still haven't found the short or other reason the front headlight won't come on, so I'm going to start by pulling the battery off the 1994, putting it on trickle charge and then prepping to go through the front wiring harness and headlight circuit slowly and painstakingly with a multi-meter.

I have rarely done electrical work, and never this kind of trouble shooting.  Ugh.

Kawasaki Concours electrical gremlin

So, how would a gremlin bell/biker bell look on a classic sport-tourer?

I've developed an electrical problem somewhere between a likely near-death battery and the headlight on my 1986 Kawasaki Concours.  I'm not a very good mechanic, and I'm even worse when it comes to electrical problems.  So tonight I'm sitting down with a cool glass of water, my pipe and the instruction manual for my Harbor Freight multi-meter.  Then I'm slowly going through the headlight circuit, left handlebar switch and anything else I can think of to find what's wrong.  I've got to get this bike back on the road-not only is it my running bike, much more economical than my 1975 stepside Chevy truck, it's also getting close to the 100K mile mark!

I'll update the blog later once I get a working headlight on this bike!

One little blade connector....

My Kawasaki Concours headlight has been giving me fits.  Earlier this week it flat out stopped working, and has intermittent getting home last night.  Not the safest operation, but due to the trailer I own with some friends being on another task this week I had to get it home somehow.

Well, today on the ride in to work it wouldn't come back on.  When I got stopped, one connector was way loose.  I shut the bike down, took the gloves off and tried to adjust it.  "tink tink tink thud" but very faint.  Looking down into the headlight housing/main fairing area I notice a bare wire sticking up.  I kneel next to the bike and there on the ground is an old, beat-up blade connector that wasn't there earlier.  GREAT.

Going to scavenge a pair of needle nose pliers from the restaurant row/Starbucks here if I can and at least try to get it back on.  If not, will have to go to plan B.

Phooey-not riding today

Another beautiful Saturday here in San Diego, but I've got lots to do, and almost none of it is motorcycle maintenance!  Cleaning out garage slowly but surely, replacing the strings on a 12-string guitar I'm trading for a chopper project bike (more on that if it happens!) and other similiar projects.

Not fun, but has to be done.  Later.

Just "De-oil" With It and First Ride on new-to-me 1996 Connie

As I got ready for a monster motorcycle maintenance session today, I told my youngest daughter I was going to degrease my 1986 Connie to try to find an oil leak.  So we started talking about why the term is degreasing instead of de-oiling, since in most cases we are removing mainly oil but sometimes grease, other lubes, brake and fork fluid, etc.  So "de-oiling" became our term, and one of us coined the phrase that is the title of this post-"Just De-oil With It".

The 86 Connie has a pretty consistent oil leak, maybe two, and is really dirty, gritty and nasty on the bottom of the bike from the oil getting everywhere and then picking up road dust, dirt and other junk. Besides not looking good and making the bike probably run a little hotter, it's starting to get on my pants when I ride.  I'd like to find the leaks and repair them.  Originally I wasn't going to if they had stayed small and I was closer to 100K, but I'm at about 92.6K and the leaks are sometimes pretty bad.  So I spent about an hour and a half wiping, cleaning and generally taking care of Miss Swail.  The final drive housing, aka the "pumpkin" used to be almost solid black!  It appears the leak is coming from the back of the water pump or the alternator shaft, which means a pretty major job.  Not routine motorcycle maintenance, but not pulling the bevel gear either!

I also got most the critical parts back on and working on the 1996 Connie.  The replacement front brake set isn't bleeding quite right still, but I was dying to take it on a test ride, and needed to get some fuel through the carbs, so I got the main fairing and mirrors back on, suited up and went for a short, conservative test ride, especially since I didn't have much in the way of brakes.  I had to cross Miss Swail's tank over, as "Belle's" tank leaks badly in the usual lower "corner" spot.  Very difficult to fix, so I may just move the tank over and repaint it when I retire Miss Swail.  It also appears the left front fork seal is failing, but I can try a few things and have an upgrade set of springs from the Connie forum.

Over-all a good day and I got a good deal done.  I'll look for leaks again tomorrow and see if any are more apparent.

Kawasaki Concours Projects weekend-started last night

After finally getting it titled and registered in my name, it's time to get the 1994 Concours on the road and get serious about finding and fixing the leaks on Miss Swail.  I actually got started on the projects last night, as I had some time and renewed desire to get the new front brake system on the 1994 bled.  Well it's still not wanting to completely bleed, so I moved on to re-installing the main fairing stay, main fairing and speedometer.

Here's a helpful hint for Connie owners that do alot of work on the front of their bike and often find themselves working alone:  If you take the main fairing off the stay and then the stay off the bike, you can do it by yourself much more easily than rigging a way to hold all the weight together.  I learned this sorting out the broken main fairing stay on Miss Swail.  So I ran up to Home Depot (the other H D) to get some replacement fasteners as some were missing or beat up.  I quickly mounted the main fairing stay (BTW the fairing to frame bolts are 8x1.25 and probably 20mm long, but I forget and am not in my shop).  Then it came time to mount the fairing.  Here it does get a little tricky with only one person, but I've found getting 1 of the 6x1.0 nuts on the two post "tabs" on each side will hold it in place while you insert the bolts on each side of the fairing, route wiring, and then add and tighten the other two nuts.  One thing I didn't do and I wish I had was I didn't wipe down the wiring harness with a moist rag to clean it up-between the blown brake caliper and dust it's a pretty big mess.  If it comes back off I'm definitely doing that.

Battery is dead from sitting since February, so I left it on the trickle charger last night and will re-install it, the main fuse (stolen for Miss Swail when I blew that one....) and move the good fuel tank over.  I'll try to fire it up and test ride it, soft front brakes and all, tomorrow afternoon.  Fortunately I live on a quiet street and have a parking lot right around the corner for testing, or I'd really sort the front brakes out first.  Due to the damage when the front left caliper blew, it may take a bit more work to get them right.  I'll post more as the work progresses, and as I hunt the leak on Miss Swail.

Great day to ride and Poker Run/motorcycle ride raffle prize idea

After a brief hot spell in San Diego County that set records, we're back to our usual beautiful weather.  The "heat wave" wasn't too bad, as we rode about 180 miles Saturday and only one stretch was particularly hot.  As part of CMAs annual Run for the Son the San Diego streetbike chapters did a big loop around the county, and while we rode down from Laguna to Campo and the 94 stretch from east to west it was a little bit warm but not too bad.  Tempuratures were in the high 80s and low 90s since we passed through in the late morning and got to the Barrett Junction Cafe around 12:30.  This is a stretch of road you sure don't want to ride at 3 or 4 in the afternoon in the worst of our summer/early fall!  This morning it's much cooler and the highs are back in the 70s for most of San Diego county.  Yep, as always, blessed to live out here at least weather-wise!

OK, here's the idea on a cheap if not free way to built a decent raffle basket for poker runs or other motorcycle rides.  Harbor Freight (www.harborfreight.com) always runs ads in motorcycle and car magazines, includes coupons in mailers, and generally has on-line ads that include freebies.  You can get one freebie per day, even if you don't make a purchase!  My current coupons include a magnetic tool dish, a "fluke" multi-meter, a clamp and other assorted tools.  Sure, none of these are professional mechanic quality, but you can't beat free.  If one of your group of riders lives or works near a Harbor Freight, why not swing by every week or two, grab one of the freebies and throw it in a box?  Every three months or so, you'd have a collection of items that would get a few tickets during a raffle.  While I didn't ask the manager of the Harbor Freight on Miramar Road here in San Diego, I bet if I nicely mentioned why I was collecting the items, they'd let me cash more than one coupon, or throw other stuff in.  It never hurts to ask, right?  BTW I am starting a box of items for this year's EXTORTION ONE SEVEN Memorial Poker Run.

One project done but more keep piling up

Yesterday I got the front wheel and new tire back from Poway Motorcycle and mounted them on the Concours.  This motorcycle maintenance project is not that hard, and all of it except the actual mounting of the wheel to the bike/lining up the axle is easily done by one person.  Actually it's probably best done by one person, but lining up the axle and getting it through forks, collar, wheel, speedo drive and other fork took some doing.  But I've got a brand new tire from BikeBandit on the bike.  This one will probably take me through to 100K.


Yesterday and today the new front tire and inner tube for my friend's 2004 Harley-Davidson Sportster 1200C arrived, so we're going to pull that front wheel off the bike, run it to Poway Motorcycles to have the new tire put on (with a tube ready to go, just in case) and then remount it.  Should be a straightforward project, but one interesting difference is the star-headed bolts holding the brake caliper on the bike.  Not sure I have a wrench or socket that fits those.


I also still need to bleed the front brakes on the 1994 Connie, then re-mount the front fairing stay, accessories and front fairing to optest the bike.  One at a time....

Kawasaki Concours C10 Front Brake System change-out

I've started restoring the 1994 Kawasaki Concours C10.  One issue that was apparent right off the bat was the front brakes were clamped to the rotors.  Shortly after buying the bike I pulled the left front caliper and found out that the seals were blown and one pad was worn down to nothing.  As I researched rebuild kits and read how to do it, I also searched the Concours forum for tips and tricks.  I also checked "The Emporium" where folks list bikes and parts for sale or needed.  Lo and behold, a member had a full brake set-up for sale for not much more than one rebuild kit!  By full, I mean FULL, from lever to pretty good brake pads!  So I ordered them and had him throw in some other parts including a matching clutch lever and master cylinder.  Time to schedule a major motorcycle maintenance project....

Unfortunately the parts came while I was on the road for work for what seemed like forever.  No bike riding, no motorcycle projects-these trips even went over weekends.  Finally at home last Saturday, I decided to ride my other C10 (Miss Swail) and put off the Connie repairs until tonight.  I was able to get some time this evening, so I put on some coffee, put the iPod in the speakers on shuffle and got to work.  I shot some video so I'll also make a YouTube video.  The old set-up came off very easily.  While the fasteners were dirty or worn, none of them were too hard to get out.  Things were still pretty messy, which is to be expected when doing maintenance on older and semi-neglected bikes.  The right side brake pads weren't too badly worn so hopefully the rotors are ok.  I checked out the replacement set-up, got the bolts from the old set I would need and went to work re-installing the set.  The right side brake calipers didn't want to cooperate and took most my time, but over-all everything went right back on pretty well.  I might pull them off and clean them up some more, but right now they are a big improvement cosmetically.  I still need to bleed the brakes fully, but the fluid in them looks brand new, another encouraging sign.

Here's the tools and parts you'll need if doing this job (and I'd bet 1980/1990s Ninja as well):

8, 10, and 12 mm wrenches (I have a three headed t-wrench that works great, but you'll still need box end wrenches for bleeder valves)
5mm allen key (for handlebar clamp)
phillips head screw driver for brake reservoir cover
DOT 4 brake fluid
rags

I didn't have to remove any lines or banjo bolts.  It took a little finagling to get the reservoir and lever past the throttle cables, but that was much easier than either disconnecting a brake line or the cables.

Goal is to get main fairing re-installed, move my non-leaking tank from the other Concours, bleed the brakes and do a road test.  Oh yeah, also need to change Miss Swail's front tire, so plenty of motorcycle maintenance projects still to do!